WO2022217280A1 - Procédé d'amélioration de l'efficacité de conversion de carbone - Google Patents

Procédé d'amélioration de l'efficacité de conversion de carbone Download PDF

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Publication number
WO2022217280A1
WO2022217280A1 PCT/US2022/071637 US2022071637W WO2022217280A1 WO 2022217280 A1 WO2022217280 A1 WO 2022217280A1 US 2022071637 W US2022071637 W US 2022071637W WO 2022217280 A1 WO2022217280 A1 WO 2022217280A1
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module
stream
fermentation
gas
passed
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PCT/US2022/071637
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English (en)
Inventor
Robert John CONRADO
Sean Dennis Simpson
Michael Emerson Martin
Jason Carl Bromley
Richard Russell Rosin
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Lanzatech, Inc.
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Priority to CN202280026186.0A priority Critical patent/CN117098851A/zh
Priority to EP22785664.8A priority patent/EP4320248A1/fr
Priority to JP2023560267A priority patent/JP2024514490A/ja
Priority to AU2022253075A priority patent/AU2022253075A1/en
Priority to CA3213229A priority patent/CA3213229A1/fr
Publication of WO2022217280A1 publication Critical patent/WO2022217280A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
    • C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
    • C10K3/026—Increasing the carbon monoxide content, e.g. reverse water-gas shift [RWGS]
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2455—Stationary reactors without moving elements inside provoking a loop type movement of the reactants
    • B01J19/2465—Stationary reactors without moving elements inside provoking a loop type movement of the reactants externally, i.e. the mixture leaving the vessel and subsequently re-entering it
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/40—Carbon monoxide
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C10G2/35—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of another activation, e.g. radiation, vibration, electrical or electromagnetic means
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/02—Liquid carbonaceous fuels essentially based on components consisting of carbon, hydrogen, and oxygen only
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/12—Bioreactors or fermenters specially adapted for specific uses for producing fuels or solvents
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M43/00—Combinations of bioreactors or fermenters with other apparatus
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • C12P7/065—Ethanol, i.e. non-beverage with microorganisms other than yeasts
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/18—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic polyhydric
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/40—Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/54—Acetic acid
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
    • C25B1/01—Products
    • C25B1/02—Hydrogen or oxygen
    • C25B1/04—Hydrogen or oxygen by electrolysis of water
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B15/00—Operating or servicing cells
    • C25B15/08—Supplying or removing reactants or electrolytes; Regeneration of electrolytes
    • C25B15/081—Supplying products to non-electrochemical reactors that are combined with the electrochemical cell, e.g. Sabatier reactor
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/26—Composting, fermenting or anaerobic digestion fuel components or materials from which fuels are prepared
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M43/00—Combinations of bioreactors or fermenters with other apparatus
    • C12M43/04—Bioreactors or fermenters combined with combustion devices or plants, e.g. for carbon dioxide removal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel

Definitions

  • the disclosure relates to processes and methods for improving carbon conversion efficiency.
  • the disclosure relates to the combination of a carbon monoxide- consuming process with an industrial process or with syngas, wherein gas from the industrial process or syngas undergoes treatment and conversion, and carbon dioxide produced by the carbon monoxide-consuming process is recycled to increase product yield.
  • Carbon dioxide ( CO 2 ) accounts for about 76% of global greenhouse gas emissions from human activities, with methane (16%), nitrous oxide (6%), and fluorinated gases (2%) accounting for the balance (United States Environmental Protection Agency). Reduction of greenhouse gas emissions, particularly CO 2 , is critical to halt the progression of global warming and the accompanying shifts in climate and weather.
  • Such gases may be derived, for example, from industrial processes, including gas emissions from carbohydrate fermentation, gas fermentation, cement making, pulp and paper making, steel making, oil refining and associated processes, petrochemical production, coke production, anaerobic or aerobic digestion, gasification, natural gas extraction, oil extraction, metallurgical processes, production and/or refinement of aluminum, copper, and/or ferroalloys, geological reservoirs, Fischer-Tropsch processes, methanol production, pyrolysis, steam methane reforming, dry methane reforming, partial oxidation of biogas or natural gas, and autothermal reforming of biogas or natural gas.
  • industrial processes including gas emissions from carbohydrate fermentation, gas fermentation, cement making, pulp and paper making, steel making, oil refining and associated processes, petrochemical production, coke production, anaerobic or aerobic digestion, gasification, natural gas extraction, oil extraction, metallurgical processes, production and/or refinement of aluminum, copper, and/or ferroalloys, geological
  • an industrial gas may require a combination of treatment and conversion. Accordingly, there remains a need for improved integration of industrial processes with CO-consuming processes, including processes for treatment and conversion of industrial gases, thereby optimizing carbon conversion efficiency.
  • a process for improving carbon conversion efficiency comprises a) passing a CO 2 -containing gaseous substrate from an industrial process, a synthesis gas process, or a combination thereof, to at least one removal module for removal of at least one constituent from the CO 2 -containing gaseous substrate, to produce a treated gas stream, comprising at least a portion of CO 2 ; b)passing the treated gas stream to a CO 2 to CO conversion system for conversion of at least a portion of the CO 2 to produce a first CO-enriched stream, wherein the CO 2 to CO conversion system is selected from reverse water gas reaction system, thermo-catalytic conversion system, electro-catalytic conversion system, partial combustion system, or plasma conversion system; c) passing at least a portion of the first CO- enriched stream to a bioreactor comprising a culture of at least one C l -fixing microorganism; d) fermenting the culture to produce one or more fermentation products and a post-fermentation gaseous substrate comprising CO 2 and H 2
  • the industrial process may be selected from industrial process is selected from fermentation, carbohydrate fermentation, sugar fermentation, cellulosic fermentation, gas fermentation, cement making, pulp and paper making, steel making, oil refining, petrochemical production, coke production, anaerobic digestion, aerobic digestion, natural gas extraction, oil extraction, geological reservoirs, metallurgical processes, refinement of aluminium, copper and or ferroalloys, for production of aluminium, copper, and or ferroalloys, direct air capture, or any combination thereof; or the synthesis gas process is selected from gasification of coal, gasification of refinery residues, gasification of petroleum coke, gasification of biomass, gasification of lignocellulosic material, gasification of waste wood, gasification of black liquor.
  • the H 2 -rich stream may be generated using a water electrolyzer and at least a portion of the H 2 -rich stream may be blended with the CO-enriched stream prior to being passed to the bioreactor or at least a portion of the th-rich stream may be passed to the bioreactor; or both at least a portion of the H 2 -rich stream may be blended with the CO-enriched stream prior to being passed to the bioreactor and at least a portion of the H 2 -rich stream may be passed to the bioreactor.
  • the process the CO-enriched stream from the CO 2 to CO conversion system may be passed to a removal module prior to being passed to the bioreactor.
  • the at least one constituent may be removed from a) the CO-enriched stream; b) the CO 2 -containing gas substrate; and or c) the post-fermentation gaseous substrate; and may be selected from sulfur-comprising compounds, aromatic compounds, alkynes, alkenes, alkanes, olefins, nitrogen-comprising compounds, oxygen, phosphorous-comprising compounds, particulate matter, solids, oxygen, halogenated compounds, silicon-comprising compounds, carbonyls, metals, alcohols, esters, ketones, peroxides, aldehydes, ethers, tars, and naphthalene.
  • the at least one constituent removed from the CO-enriched stream by the removal module may comprise oxygen.
  • the at least one constituent removed and/or converted may be a microbe inhibitor and/or a catalyst inhibitor.
  • the at least one constituent removed may be produced, introduced, and/or concentrated by the fermentation step.
  • the at least one constituent removed may be produced, introduced, and/or concentrated by the CO 2 to CO conversion system.
  • the Cl-fixing microorganism may be a carboxydotrophic bacterium.
  • the carboxydotrophic bacterium may be selected from the group comprising Moorella, Clostridium, Ruminococcus, Acetobactcrium, Eubacterium, Butyribacterium, Oxobacfer, Methanosarcina , and Desulfotomaculum.
  • the carboxydotrophic bacterium may be Clostridium autoethamogenum .
  • the COi-containing gaseous substrate may be passed to a carbon dioxide concentration module to enhance the level of carbon dioxide contained in (i ) the CO 2 -containing gaseous substrate prior to the COi-containing gaseous substrate being passed to the one or more removal module, (ii) the treated gas stream comprising at least a portion of carbon dioxide prior to the treated gas stream being passed to the water electrolyzer; and/or (iii) the post- fermentation gaseous substrate prior to the post-fermentation gaseous substrate being passed to the one or more removal modules, or the bioreactor.
  • the CO 2 -containing gaseous substrate from the industrial process, the synthesis gas process, or the combination thereof may be passed to a pressure module to produce a pressurized CO 2- containing gas stream and then passing the pressurized CO 2 -containing gas stream to the fust removal module.
  • the CO-enriched stream may be passed to a pressure module to produce a pressurized CO-stream and the pressurized CO-stream may be passed to the bioreactor.
  • the at least one removal module may be selected from hydrolysis module, acid gas removal module, deoxygenation module, catalytic hydrogenation module, particulate removal module, chloride removal module, tar removal module, or hydrogen cyanide polishing module.
  • the at least one fermentation product may be selected from ethanol, butyrate, 2,3- butanediol, lactate, butene, butadiene, methyl ethyl ketone, ethylene, acetone, isopropanol, lipids, 3-hydroypropionate, terpenes, fatty acids, 2-butanol, 1,2-propanediol, or 1-propanol.
  • the at least one of the fermentation product maybe further converted to at least one component of diesel, jet fuel, and/or gasoline.
  • the at least one fermentation product may comprise microbial biomass. At least a portion of the microbial biomass may be processed to produce at least a portion of animal feed.
  • the CO-enriched stream may comprise at least a portion of oxygen, and at least a portion of the CO-enriched stream may be passed to an oxygen separation module to separate at least a portion of oxygen from the carbon monoxide enriched stream.
  • a process for improving process economics of an integrated industrial fermentation system comprises ajpassing a feedstock comprising water to a water electrolyzer, wherein at least a portion of the water is converted to H 2 and O 2 ; b) passing a CO 2 -containing gaseous substrate to a reverse water gas shift process to generate a CO- enriched stream; c) passing at least a portion of the H 2 and at least a portion of the CO-enriched stream from the reverse water gas shift process to a bioreactor containing a culture of at least one Cl -fixing microorganism; d) fermenting the culture to produce one or more fermentation products and a post-fermentation gaseous substrate comprising CO 2 and H 2 ; and e) passing at least a portion of the post-fermentation gaseous substrate back to the reverse water gas shift process.
  • the amount of CO 2 in the post-femientation gaseous substrate exiting the bioreactor may be greater than an amount of unconverted CO 2 introduced to the bioreactor.
  • the fermentation process may perform the function of a CO 2 concentration module.
  • Figure lA shows a process integration scheme depicting integration of a removal module, a CO 2 to CO conversion system, and an optional water electrolysis module with a CO- consuming process.
  • Figure IB further shows a pressure module prior to a removal module.
  • Figure 1C further shows a pressure module prior to a CO-consuming process.
  • Figure 2 show's a process integration scheme depicting integration of a removal module, a CO 2 to CO conversion system, an optional O 2 separation module, and an optional water electrolysis module with a CO-consuming process.
  • Figure 3 show's a process integration scheme depicting integration of an optional CO 2 concentration module prior to a removal module, a CO 2 to CO conversion system, an optional water electrolysis module, and an optional O 2 separation module with a CO-consuming process.
  • Figure 4 show's a process integration scheme depicting integration of an optional CO 2 concentration module following a removal module, a CO 2 to CO conversion system, an optional w'ater electrolysis module, and an optional O 2 separation module with a CO- consuming process.
  • Figure 5 show's a process integration scheme depicting integration of a water electrolysis module following an optional pressure module, w'herein a portion of the gas from the w'ater electrolysis module is blended with the gas from the CO 2 to CO conversion system prior to being passed to the CO-consuming process.
  • Figure 6 shows a process integration scheme depicting integration of a further removal module following a CO 2 to CO conversion system.
  • the inventors have identified that the integration of a CO 2 -generating industrial process with a CO-consuming process, as well as a removal process prior to a CO 2 to CO conversion process, is capable of providing substantial benefits to the CO 2 -generating industrial process and the CO-consuming process, which may be a C 1 -fixing fermentation process.
  • the term “industrial process” refers to a process for producing, converting, refining, reforming, extracting, or oxidizing a substance involving chemical, physical, electrical, and/or mechanical steps.
  • Exemplary industrial processes include, but are not limited to, carbohydrate fermentation, gas fermentation, cement making, pulp and paper making, steel making, oil refining and associated processes, petrochemical production, coke production, anaerobic or aerobic digestion, gasification (such as gasification of biomass, liquid waste streams, solid waste streams, municipal streams, fossil resources including natural gas, coal and oil), natural gas extraction, oil extraction, metallurgical processes, production and/or refinement of aluminum, copper, and/or ferroalloys, geological reservoirs, Fischer-Tropsch processes, methanol production, pyrolysis, steam methane reforming, dry methane reforming, partial oxidation of biogas or natural gas, direct air capture, and autothermal reforming of biogas or natural gas.
  • the substrate and/or Cl -carbon source include, but are
  • gas from an industrial process can be used interchangeably to refer to an off-gas from an industrial process, a by-product of an industrial process, a co-product of an industrial process, a gas recycled within an industrial process, and/or a gas used within an industrial facility for energy recovery.
  • a gas from an industrial process is a pressure swing adsorption (PSA) tail gas.
  • PSA pressure swing adsorption
  • a gas from an industrial process is a gas obtained through a CO 2 extraction process, which may involve amine scrubbing or use of a carbonic anhydrase solution.
  • Cl refers to a one-carbon molecule, for example, CO, CO 2 , methane (CH 4 ), or methanol (CH 3 OH).
  • C1 -oxygenate refers to a one-carbon molecule that also comprises at least one oxygen atom, for example, CO, CO 2 , or CH 3 OH.
  • Cl -carbon source refers a one carbon-molecule that serves as a partial or sole carbon source for a microorganism of the disclosure.
  • a Cl -carbon source may comprise one or more of CO, CO 2 , CH 4 , CH 3 OH, or formic acid (CH 2 O 2 ).
  • a Cl -carbon source comprises one or both of CO and CO 2 .
  • a “Cl -fixing microorganism” is a microorganism that has the ability to produce one or more products from a C 1 -carbon source.
  • a microorganism of the disclosure is a C 1 -fixing bacterium.
  • “Substrate” refers to a carbon and/or energy source. Typically, the substrate is gaseous and comprises a C 1 -carbon source, for example, CO, CO 2 , and/or CH 4 . Preferably, the substrate comprises a C1 -carbon source of CO or CO and CO 2 . The substrate may further comprise other non-carbon components, such as H 2 , N 2 , or electrons. As used herein, “substrate” may refer to a carbon and/or energy source for a microorganism of the disclosure. [0028] The term “co-substrate” refers to a substance that, while not necessarily being the primary energy and material source for product synthesis, can be utilized for product synthesis when combined with another substrate, such as the primary substrate.
  • a “CO 2 -comprising gaseous substrate,” “CO 2 -comprising gas,” or “ CO- 2 comprising gaseous source” may include any gas that comprises CO 2 .
  • the gaseous substrate will typically comprise a significant proportion of CO 2 , preferably at least about 5% to about 100% CO 2 by volume. Additionally, the gaseous substrate may comprise one or more of hydrogen (H 2 ), oxygen (O 2 ), nitrogen (N 2 ), and/or CH 4 .
  • H 2 , and CH 4 may be referred to as “energy-rich gases.”
  • carbon capture refers to the sequestration of carbon compounds including CO 2 and/or CO from a stream comprising CO 2 and/or CO and either a) converting the CO 2 and/or CO into products, b) converting the CO 2 and/or CO into substances suitable for long term storage, c) trapping the CO 2 and/or CO in substances suitable for long term storage, or d) a combination of these processes.
  • incrementing the efficiency refers to an increase in the rate and/or output of a reaction, such as an increased rate of converting the CO 2 and/or CO into products and/or an increased product concentration.
  • increasing the efficiency includes, but is not limited to, increasing one or more of the rate of growth of microorganisms catalyzing a fermentation, the growth and/or product production rate at elevated product concentrations, the volume of desired product produced per volume of substrate consumed, the rate of production or level of production of the desired product, and the relative proportion of the desired product produced compared with other by-products of the fermentation.
  • reactant refers to a substance that is present in a chemical reaction and is consumed during the reaction to produce a product.
  • a reactant is a starting material that undergoes a change during a chemical reaction.
  • a reactant includes, but is not limited to, CO and/or H 2 .
  • a reactant is CO 2 .
  • a “CO-consuming process” refers to a process wherein CO is a reactant; CO is consumed to produce a product.
  • a non-limiting example of a CO-consuming process is a Cl- fixing gas fermentation process.
  • a CO-consuming process may involve a CO 2 -producing reaction.
  • a CO-consuming process may result in the production of at least one product, such as a fermentation product, as well as CO 2 .
  • acetic acid production is a CO-consuming process, wherein CO is reacted with methanol under pressure.
  • Gas stream refers to any stream of substrate which is capable of being passed, for example, from one module to another, from one module to a CO-consuming process, and/or from one module to a carbon capture means.
  • Gas streams typically will not be a pure CO 2 stream and will comprise proportions of at least one other component.
  • each source may have differing proportions of CO 2 , CO, H 2 , and various constituents. Due to the varying proportions, a gas stream must be processed prior to being introduced to a CO-consuming process. Processing of the gas stream includes the removal and/or conversion of various constituents that may be microbe inhibitors and/or catalyst inhibitors.
  • catalyst inhibitors are removed and/or converted prior to being passed to the CO 2 to CO conversion process, and microbe inhibitors are removed and/or converted prior to being passed to a CO-consuming process.
  • a gas stream may need to undergo one or more concentration steps whereby the concentration of CO and/or CO 2 is increased.
  • a gas stream will undergo a concentration step to increase the concentration of CO 2 prior to being passed to the CO 2 to CO conversion process. It has been found that higher concentrations of CO 2 being passing into the CO 2 to CO conversion process results in higher concentrations of CO coming out of the CO 2 to CO conversion process.
  • Removal module includes hydrolysis modules, acid gas removal modules, deoxygenation modules, catalytic hydrogenation modules, particulate removal modules, chloride removal modules, tar removal modules, and hydrogen cyanide polishing modules.
  • constituents refer to the microbe inhibitors and/or catalyst inhibitors that may be found in a gas stream.
  • the constituents include, but are not limited to, sulfur-comprising compounds, aromatic compounds, alkynes, alkenes, alkanes, olefins, nitrogen-comprising compounds, phosphorous-comprising compounds, particulate matter, solids, oxygen, halogenated compounds, silicon-comprising compounds, carbonyls, metals, alcohols, esters, ketones, peroxides, aldehydes, ethers, tars, and naphthalene.
  • the constituent removed by the removal module does not include CO 2 .
  • “Microbe inhibitors” as used herein refer to one or more constituents that slow down or prevent a particular chemical reaction or other process, including the microbe.
  • the microbe inhibitors include, but are not limited to, oxygen (O 2 ), hydrogen cyanide (HCN), acetylene (C 2 H 2 ), and BTEX (benzene, toluene, ethyl benzene, xylene).
  • Catalyst inhibitor refers to one or more substances that decrease the rate of or prevent a chemical reaction.
  • the catalyst inhibitors may include, but are not limited to, hydrogen sulfide (H 2 S) and carbonyl sulfide (COS).
  • At least one constituent removed is produced, introduced, and/or concentrated by a fermentation step.
  • One or more of these constituents may be present in a post-fermentation gaseous substrate.
  • sulfur in the form of H 2 S may be produced, introduced, and/or concentrated by a fermentation step.
  • hydrogen sulfide is introduced in the fermentation step.
  • the post-fermentation gaseous substrate comprises at least a portion of hydrogen sulfide.
  • Hydrogen sulfide may be a catalyst inhibitor. Hydrogen sulfide may be inhibiting to particular the CO 2 to CO conversion process, if employed.
  • At least a portion of the hydrogen sulfide, or other constituent present in the post-fermentation gaseous substrate may need to be removed by one or more removal module.
  • acetone may be produced by a fermentation step, and charcoal may be used as a removal module.
  • treated gas and “treated gas stream” refer to a gas stream that has been passed through at least one removal module and has had one or more constituent removed and/or converted.
  • a “CO 2 -treated gas stream” refers to a CO 2 -comprising gas that has passed through one or more removal module.
  • concentration module refers to technology capable of increasing the level of a particular component in a gas stream.
  • the concentration module is a CO 2 concentration module, wherein the proportion of CO 2 in the gas stream leaving the CO 2 concentration module is higher relative to the proportion of CO 2 in the gas stream prior to being passed to the CO 2 concentration module.
  • a CO 2 concentration module uses deoxygenation technology to remove O 2 from a gas stream and thus increase the proportion of CO 2 in the gas stream.
  • a CO 2 concentration module uses pressure swing adsorption (PSA) technology to remove H 2 from a gas stream and thus increase the proportion of CO 2 in the gas stream.
  • PSA pressure swing adsorption
  • a fermentation process performs the function of a CO 2 concentration module.
  • a gas stream from a concentration module is passed to a carbon capture and sequestration (CCS) unit or an enhanced oil recovery (EOR) unit.
  • CCS carbon capture and sequestration
  • EOR enhanced oil recovery
  • CO 2 to CO conversion system refers to at least one unit selected from reverse water gas reaction system, thermo-catalytic conversion system, electro- catalytic conversion system, partial combustion system and plasma conversion system.
  • a CO 2 electrolysis module was employed as a process to convert at least some collected CO 2 to CO.
  • electricity may be cost prohibitive, not sustainable, not reliable, or not easily available. Therefore, a need exists for another solution to utilize available CO 2 waste gas.
  • the CO 2 to CO conversion system provides such solution.
  • a particular embodiment the CO 2 to CO conversion system is a reverse water gas reaction unit or system.
  • reverse water gas reaction unit / “rWGR unit” as used herein refers to a unit or system used for producing water from carbon dioxide and hydrogen, with carbon monoxide as a side product.
  • water gas is defined as a fuel gas consisting mainly of carbon monoxide (CO) and hydrogen (H 2 ).
  • shift’ in water-gas shift means changing the water gas composition (CO:H 2 ) ratio. The ratio can be increased by adding CO 2 or reduced by adding steam to the reactor.
  • the reverse water gas reaction unit may comprise a single stage or more than one stage. The different stages may be conducted at different temperatures and may use different catalysts.
  • thermo-catalytic conversion another suitable CO 2 to CO conversion system, refers to a process to disrupt the stable atomic and molecular bonds of CO 2 and other reactants over a catalyst by using thermal energy as the driving force of the reaction to produce CO. Since CO 2 molecules are thermodynamically and chemically stable, if CO 2 is used as a single reactant, large amounts of energy are required. Therefore, often other substances such as hydrogen are used as a co-reactant to make the thermodynamic process easier. Many catalysts are known for the process such as metals and metal oxides as well as nano-sized catalyst metal-organic frameworks. Various carbon materials have been employed as carriers for the catalysts.
  • partial combustion system refers to a system where oxygen supplies at least a portion of the oxidant requirement for partial oxidation and the reactants carbon dioxide and water present therein are substantially converted to carbon monoxide and hydrogen.
  • plasma conversion refers to CO 2 conversion process, focusing on the combination of plasma with catalysts, called as plasma-catalysis.
  • Plasma-catalysis also called the “fourth state of matter,” is an ionized gas consisting of electrons, various types of ions, radicals, excited atoms, and molecules, besides neutral ground state molecules.
  • the three most common plasma types for CO 2 conversion are: dielectric barrier discharges (DBDs), microwave (MW) plasmas, and gliding arc (GA) plasmas.
  • DBDs dielectric barrier discharges
  • MW microwave
  • GA gliding arc
  • “Plasma conversion system” for CO 2 conversion comprises (i) high process versatility, allowing different kinds of reactions to be carried out (e.g., pure CO 2 splitting, as well as CO 2 conversion in the presence of a H-source, such as CH4, H 2 or H 2 O); (ii) low investment and operating costs; (iii) does not require the use of rare earth metals; (iv) a very modular setting, as plasma reactors scale up linearly with the plant output, allowing on-demand production; and (v) it can be very easily combined with (various kinds of) renewable electricity.
  • electrolysis module and “electrolyzer” can be used interchangeably to refer to a unit that uses electricity to drive a non-spontaneous reaction.
  • Electrolysis technologies are known in the art. Exemplary processes include alkaline water electrolysis, proton, or anion exchange membrane (PEM, AEM) electrolysis, and solid oxide electrolysis (SOE) (Ursua el a/., Proceedings of the IEEE 100(2):410-426, 2012; Jhong et al ., Current Opinion in Chemical Engineering 2:191-199, 2013).
  • Faradaic efficiency is a value that references the number of electrons flowing through an electrolyzer and being transferred to a reduced product rather than to an unrelated process.
  • SOE modules operate at elevated temperatures. Below the thermoneutral voltage of an electrolysis module, an electrolysis reaction is endothermic. Above the thermoneutral voltage of an electrolysis module, an electrolysis reaction is exothermic. In some embodiments, an electrolysis module is operated without added pressure. In some embodiments, an electrolysis module is operated at a pressure of 5-10 bar.
  • a “CO 2 electrolysis module” refers to a unit capable of splitting CO 2 into CO and O 2 and is defined by the following stoichiometric reaction: 2CO 2 + electricity ⁇ 2CO + O 2 .
  • the use of different catalysts for CO 2 reduction impact the end product. Catalysts including, but not limited to, Au, Ag, Zn, Pd, and Ga catalysts, have been shown effective to produce CO from CO 2 .
  • the pressure of a gas stream leaving a CO 2 electrolysis module is approximately 5-7 barg.
  • Water electrolysis module and “H 2 O electrolysis module” refer to a unit capable of splitting H 2 O, in the form of steam, into H 2 and O 2 and is defined by the following stoichiometric reaction: 2H 2 O + electricity ⁇ 2H 2 + O 2 .
  • a water electrolysis module reduces protons to H 2 and oxidizes O 2' to O 2 .
  • H 2 produced by electrolysis can be blended with a Cl- comprising gaseous substrate as a means to supply additional feedstock and to improve substrate composition.
  • H 2 and CO 2 electrolysis modules have 2 gas outlets.
  • One side of the electrolysis module, the anode comprises H 2 or CO (and other gases such as unreacted water vapor or unreacted CO 2 ).
  • the second side, the cathode comprises O 2 (and potentially other gases).
  • the composition of a feedstock being passed to an electrolysis process may determine the presence of various components in a CO stream. For instance, the presence of inert components, such as CH 4 and/or N 2 , in a feedstock may result in one or more of those components being present in the CO-enriched stream. Additionally, in some electrolyzers, O 2 produced at the cathode crosses over to the anode side where CO is generated and/or CO crosses over to the anode side, leading to cross contamination of the desired gas products.
  • an “O 2 separation module” is used to refer to a technology capable of dividing a substance into two or more components.
  • an “O 2 separation module” may be used to separate an O 2 -comprising gaseous substrate into a stream comprising primarily O 2 (also referred to as an “O 2 -enriched stream” or “O 2 -rich gas”) and a stream that does not primarily comprise O 2 , comprises no O 2 , or comprises only trace amounts of O 2 (also referred to as an “O 2 -lean stream” or “02-depleted stream”).
  • enriched stream refers to a gas stream having a greater proportion of a particular component following passage through a module, such as an rWGS unit, as compared to the proportion of the component in the input stream into the module.
  • a “CO-enriched stream” may be produced upon passage of a CO 2 -comprising gaseous substrate through a CO 2 to CO conversion system such as a rWGS unit.
  • An “H 2 -enriched stream” may be produced upon passage of a water gaseous substrate through a water electrolysis module.
  • An “O 2 -enriched stream” emerges automatically from the anode of a CO 2 or water electrolysis module; an “02-enriched stream” may also be produced upon passage of an O 2 -comprising gaseous substrate through an O 2 separation module.
  • a “CO 2 -enriched stream” may be produced upon passage of a CO 2 -comprising gaseous substrate through a CO 2 concentration module.
  • the terms “lean stream,” “depleted gas,” and the like refer to a gas stream having a lesser proportion of a particular component following passage through a module, such as a concentration module or a separation module, as compared to the proportion of the component in the input stream into the module.
  • an O 2 -lean stream may be produced upon passage of an O 2 -comprising gaseous substrate through an O 2 separation module.
  • the O 2 -lean stream may comprise unreacted CO 2 from a CO 2 to CO conversion system.
  • the 02-lean stream may comprise trace amounts of O 2 or no O 2 .
  • a “CO 2 -lean stream” may be produced upon passage of a CO 2 -comprising gaseous substrate through a CO 2 concentration module.
  • the CO 2 -lean stream may comprise CO, H 2 , and/or a constituent such as a microbe inhibitor or a catalyst inhibitor.
  • the CO 2 -lean stream may comprise trace amounts of CO 2 or no CO 2 .
  • the disclosure provides an integrated process wherein the pressure of the gas stream is capable of being increased and/or decreased.
  • pressure module refers to a technology capable of producing (i.e., increasing) or decreasing the pressure of a gas stream.
  • the pressure of the gas may be increased and/or decreased through any suitable means, for example one or more compressor and/or valve.
  • a gas stream may have a lower than optimum pressure, or the pressure of the gas stream may be higher than optimal, and thus, a valve may be included to reduce the pressure.
  • a pressure module may be located before or after any module described herein. For example, a pressure module may be utilized prior to a removal module, prior to a concentration module, prior to a water electrolysis module, and/or prior to a CO-consuming process.
  • a “pressurized gas stream” refers to a gaseous substrate that has passed through a pressure module.
  • a “pressurized gas stream” may also be used to refer to a gas stream that meets the operating pressure requirements of a particular module.
  • post-CO-consuming process gaseous substrate may comprise unreacted CO, unreacted H2, and/or CO 2 produced (or not taken up in parallel) by the CO-consuming process.
  • the post-CO-consuming process gaseous substrate may further be passed to one or more pressure modules, a removal module, a CO 2 concentration module, and/or a water electrolysis module.
  • a “post-CO-consuming process gaseous substrate” is a post- fermentation gaseous substrate.
  • the term “desired composition” is used to refer to the desired level and types of components in a substance, such as, for example, of a gas stream. More particularly, a gas is considered to have a “desired composition” if it contains a particular component (i.e., CO, H 2, and/or CO 2 ) and/or contains a particular component at a particular proportion and/or does not comprise a particular component (i.e.. a contaminant harmful to the microorganisms) and/or does not comprise a particular component at a particular proportion. More than one component may be considered when determining whether a gas stream has a desired composition.
  • a particular component i.e., CO, H 2, and/or CO 2
  • More than one component may be considered when determining whether a gas stream has a desired composition.
  • the substrate comprises about 30% or less H 2 by volume, 20% or less Fh by volume, about 15% or less Fh by volume or about 10% or less Fh by volume.
  • the substrate stream comprises low concentrations of H 2 , for example, less than 5%, or less than 4%, or less than 3%, or less than 2%, or less than 1%, or is substantially Fh free.
  • the substrate may also comprise some CO for example, such as about 1% to about 80% CO by volume, or 1% to about 30% CO by volume. In one embodiment, the substrate comprises less than or equal to about 20% CO by volume. In another embodiment, the substrate comprises less than or equal to about 15% CO by volume, less than or equal to about 10% CO by volume, less than or equal to about 5% CO by volume or substantially no CO.
  • Substrate composition can be improved to provide a desired or optimum Fh:CO:CO 2 ratio.
  • the desired H 2 .CO.CO 2 ratio is dependent on the desired fermentation product of the fermentation process.
  • the optimum H 2 :CO.CO 2 ratio would be: (x): (y): where x > 2 y, in order to satisfy the stoichiometry for ethanol production:
  • a gaseous substrate comprising minimal H 2 will typically produce ethanol and CO 2 by the following stoichiometry: 6 CO + 3 H 2 O C 2 H 5 OH + 4 CO 2 .
  • the amount of H 2 utilized by the Cl fixing bacterium increase, the amount of CO 2 produced decreases, i.e., 2 CO + 4 H 2 C 2 H 5 OH
  • the composition of the substrate may have a significant impact on the efficiency and/or cost of the reaction.
  • the presence of O 2 may reduce the efficiency of an anaerobic fermentation process.
  • carbon capture can be increased by recycling CO 2 produced by a CO-consuming process back to a CO 2 to CO conversion system, thereby improving yield of the CO-consuming process.
  • CO 2 produced by the CO-consuming process may be treated prior to passage through the CO 2 to CO conversion system.
  • the CO 2 to CO conversion system is a rWGS unit, which can be single stage or two or more stages.
  • a CO-consuming process is performed in a bioreactor.
  • bioreactor includes a fermentation device consisting of one or more vessels and/or towers or piping arrangements, which includes the Continuous Stirred Tank Reactor (CSTR), Immobilized Cell Reactor (ICR), Trickle Bed Reactor (TBR), Bubble Column, Gas Lift Fermenter, Static Mixer, a circulated loop reactor, a membrane reactor, such as a Hollow Fiber Membrane Bioreactor (HFM BR) or other vessel or other device suitable for gas-liquid contact.
  • CSTR Continuous Stirred Tank Reactor
  • ICR Immobilized Cell Reactor
  • TBR Trickle Bed Reactor
  • Bubble Column Gas Lift Fermenter
  • Static Mixer Static Mixer
  • a circulated loop reactor a membrane reactor, such as a Hollow Fiber Membrane Bioreactor (HFM BR) or other vessel or other device suitable for gas-liquid contact.
  • HFM BR Hollow Fiber Membrane Bioreactor
  • the reactor is preferably adapted to receive
  • the reactor may comprise multiple reactors (stages), either in parallel or in series.
  • the reactor may comprise a first growth reactor in which the bacteria are cultured and a second fermentation reactor, to which fermentation broth from the growth reactor may be fed and in which most of the fermentation products may be produced.
  • the phrases “fermenting,” “fermentation process,” “fermentation reaction” and the like, as used herein, are intended to encompass both the growth phase and product biosynthesis phase of the gaseous substrate.
  • the fermentation is performed in the absence of carbohydrate substrates, such as sugar, starch, lignin, cellulose, or hemicellulose.
  • a culture is generally maintained in an aqueous culture medium that contains nutrients, vitamins, and/or minerals sufficient to permit growth of a microorganism.
  • “Nutrient media,” “nutrient medium,” and “culture medium” are used to describe bacterial growth media.
  • the aqueous culture medium is an anaerobic microbial growth medium, such as a minimal anaerobic microbial growth medium. Suitable media are well known in the art.
  • the tenn “nutrient” includes any substance that may be utilised in a metabolic pathway of a microorganism. Exemplary nutrients include potassium, B vitamins, trace metals, and amino acids.
  • microorganism of the disclosure may be cultured with a gas stream to produce one or more products.
  • a microorganism of the disclosure may produce or may be engineered to produce ethanol (WO 2007/117157), acetate (WO 2007/117157), butanol (WO 2008/115080 and WO 2012/053905), butyrate (WO 2008/115080), 2,3-butanediol (WO 2009/151342 and WO 2016/094334), lactate (WO 2011/112103), butene (WO 2012/024522), butadiene (WO 2012/024522), methyl ethyl ketone (2-butanone) (WO 2012/024522 and WO 2013/185123), ethylene (WO 2012/026833), acetone (WO 2012/115527), isopropanol (WO 2012/115527), lipids (WO 2013/036147), 3- hydroxypropionate (3-HP) (WO 2013/180581), terpenes, including isoprene (WO 2013/180584), fatty acids (WO 2013/191567), 2-butanol (WO 2013/
  • a microorganism of the disclosure may also produce ethanol, acetate, and/or 2,3-butanediol.
  • microbial biomass itself may be considered a product. These products may be further converted to produce at least one component of diesel, jet fuel, and/or gasoline. Additionally, the microbial biomass may be further processed to produce a single cell protein (SCP).
  • SCP single cell protein
  • a “microorganism” is a microscopic organism, especially a bacterium, archea, virus, or fungus.
  • a microorganism of the disclosure is typically a bacterium.
  • recitation of “microorganism” should be taken to encompass “bacterium.”
  • a “parental microorganism” is a microorganism used to generate a microorganism of the disclosure.
  • the parental microorganism may be a naturally occurring microorganism, known as a wild-type microorganism, or a microorganism that has been previously modified, known as a mutant or recombinant microorganism.
  • a microorganism of the disclosure may be modified to express or overexpress one or more enzymes that were not expressed or overexpressed in the parental microorganism.
  • a microorganism of the disclosure may be modified to comprise one or more genes that were not contained by the parental microorganism.
  • a microorganism of the disclosure may also be modified to not express or to express lower amounts of one or more enzymes that were expressed in the parental microorganism.
  • the parental microorganism is Clostridium autoethanogenum, Clostridium Ijungdahlii , or Clostridium ragsdalei.
  • the parental microorganism is Clostridium autoethanogenum LZ 1561, which was deposited on June 7, 2010 with Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH (DSMZ) located at Inhoffenstrahe 7B, D-38124 Braunschweig, Germany on June 7, 2010 under the terms of the Budapest Treaty and accorded accession number DSM23693. This strain is described in International Patent Application No. PCT/NZ2011/000144, which published as WO 2012/015317.
  • a microorganism of the disclosure is derived from a parental microorganism.
  • a microorganism of the disclosure is derived from Clostridium autoethanogenum, Clostridium Ijungdahlii , or Clostridium ragsdalei.
  • a microorganism of the disclosure is derived from Clostridium autoethanogenum LZ1561, which is deposited under DSMZ accession number DSM23693.
  • a microorganism of the disclosure may be further classified based on functional characteristics.
  • the microorganism of the disclosure may be or may be derived from a Cl -fixing microorganism, an anaerobe, an acetogen, an ethanologen, a carboxydotroph, and/or a methanotroph.
  • Wood-Ljungdahl refers to the Wood-Ljungdahl pathway of carbon fixation as described, i.e., by Ragsdale, Biochim Biophys Acta, 1784: 1873-1898, 2008.
  • Wood-Ljungdahl microorganisms refers, predictably, to microorganisms comprising the Wood-Ljungdahl pathway.
  • a microorganism of the disclosure contains a native Wood-Ljungdahl pathway.
  • a Wood-Ljungdahl pathway may be a native, unmodified Wood-Ljungdahl pathway or it may be a Wood-Ljungdahl pathway with some degree of genetic modification (i.e., overexpression, heterologous expression, knockout, etc.) so long as it still functions to convert CO, CO 2 , and/or H 2 to acetyl-CoA.
  • An “anaerobe” is a microorganism that does not require O 2 for growth.
  • An anaerobe may react negatively or even die if O 2 is present above a certain threshold. However, some anaerobes can tolerate low levels of O 2 (i.e., 0.000001-5% O 2 ).
  • a microorganism of the disclosure is an anaerobe.
  • Acetogens are obligately anaerobic bacteria that use the Wood-Ljungdahl pathway as their main mechanism for energy conservation and for synthesis of acetyl-CoA and acetyl- CoA-derived products, such as acetate (Ragsdale, Biochim Biophys Acta , 1784: 1873-1898, 2008).
  • acetogens use the Wood-Ljungdahl pathway as a (1) mechanism for the reductive synthesis of acetyl-CoA from CO 2 , (2) terminal electron-accepting, energy conserving process, (3) mechanism for the fixation (assimilation) of CO 2 in the synthesis of cell carbon (Drake, Acetogenic Prokaryotes, In: The Prokaryotes, 3 rd edition, p. 354, New York, NY, 2006). All naturally occurring acetogens are Cl -fixing, anaerobic, autotrophic, and non-methanotrophic. Typically, a microorganism of the disclosure is an acetogen.
  • An “ethanologen” is a microorganism that produces or is capable of producing ethanol.
  • a microorganism of the disclosure is an ethanologen.
  • An “autotroph” is a microorganism capable of growing in the absence of organic carbon. Instead, autotrophs use inorganic carbon sources, such as CO and/or CO 2 . Typically, a microorganism of the disclosure is an auto roph.
  • a “carboxydotroph” is a microorganism capable of utilizing CO as a sole source of carbon and energy. Typically, a microorganism of the disclosure is a carboxydotroph.
  • a “methanotroph” is a microorganism capable of utilizing methane as a sole source of carbon and energy.
  • a microorganism of the disclosure is a methanotroph or is derived from a methanotroph.
  • a microorganism of the disclosure is not a methanotroph or is not derived from a methanotroph.
  • Table 1 provides a representative list of microorganisms and identifies their functional characteristics.
  • Acetobacterhim woodii can produce ethanol from fructose, but not from gas.
  • a “native product” is a product produced by a genetically unmodified microorganism.
  • ethanol, acetate, and 2,3-butanediol are native products of Clostridium autoethanogenum , Clostridium ljungdahlii, and Clostridium ragsdalei.
  • a “non-native product” is a product that is produced by a genetically modified microorganism but is not produced by a genetically unmodified microorganism from which the genetically modified microorganism is derived.
  • Selectivity refers to the ratio of the production of a target product to the production of all fermentation products produced by a microorganism.
  • a microorganism of the disclosure may be engineered to produce products at a certain selectivity or at a minimum selectivity.
  • a target product account for at least about 5%, 10%, 15%, 20%, 30%, 50%, or 75% of all fermentation products produced by a microorganism of the disclosure.
  • the target product accounts for at least 10% of all fermentation products produced by a microorganism of the disclosure, such that a microorganism of the disclosure has a selectivity for the target product of at least 10%.
  • the target product accounts for at least 30% of all fermentation products produced by a microorganism of the disclosure, such that a microorganism of the disclosure has a selectivity for the target product of at least 30%.
  • a culture/ fermentation should desirably be carried out under appropriate conditions for production of the target product.
  • the culture/fermentation is performed under anaerobic conditions.
  • Reaction conditions to consider include pressure (or partial pressure), temperature, gas flow rate, liquid flow rate, media pH, media redox potential, agitation rate (if using a continuous stirred tank reactor), inoculum level, maximum gas substrate concentrations to ensure that gas in the liquid phase does not become limiting, and maximum product concentrations to avoid product inhibition.
  • the rate of introduction of the substrate may be controlled to ensure that the concentration of gas in the liquid phase does not become limiting, since products may be consumed by the culture under gas-limited conditions.
  • Target products may be separated or purified from a fermentation broth using any method or combination of methods known in the art, including, for example, fractional distillation, evaporation, pervaporation, gas stripping, phase separation, and extractive fermentation, including for example, liquid-liquid extraction.
  • target products are recovered from the fermentation broth by continuously removing a portion of the broth from the bioreactor, separating microbial cells from the broth (conveniently by filtration), and recovering one or more target products from the broth.
  • Alcohols and/or acetone may be recovered, for example, by distillation.
  • Acids may be recovered, for example, by adsorption on activated charcoal.
  • Separated microbial cells are preferably returned to the bioreactor.
  • the cell- free permeate remaining after target products have been removed is also preferably returned to the bioreactor. Additional nutrients (such as B vitamins) may be added to the cell-free permeate to replenish the medium before it is returned to the bioreactor.
  • Figure 1A shows a process for integration of an industrial process 110, one or more removal module 120, a CO 2 to CO conversion system 130, an optional water electrolysis process 160, and a CO-consuming process 140.
  • CO 2 -comprising gas from an industrial process 110 is fed via a conduit 112 to one or more removal module 120 to remove and/or convert one or more constituent 128.
  • CO 2 to CO conversion system 130 is a rWGS unit.
  • the r WGS unit has a single stage.
  • the rWGS unit has at least two stages.
  • the treated gas from the one or more removal modules 120 is then fed via a conduit 122 to CO 2 to CO conversion system 130 for conversion of at least a portion of the gas stream.
  • CO 2 -comprising gas from the industrial process 110 is directly fed via a conduit 114 to CO 2 to CO conversion system 130 for conversion of at least a portion of the gas stream; in this embodiment, a constituent such as sulfur-comprising compound may be removed prior to passage through an industrial process.
  • a constituent such as sulfur-comprising compound may be removed prior to passage through an industrial process.
  • at least a portion of the H 2 O perhaps in the form of vapor or steam that is generated as a product of the reverse water gas shift reaction may be recycled from the CO 2 to CO conversion system 130 to the industrial process 110 via a conduit 136.
  • At least a portion of the converted gas stream is passed, via a conduit 132, from the CO 2 to CO conversion system 130, which in this example is a rWGS unit, to a CO-consuming process 140.
  • a water substrate is fed via a conduit 162 to a water electrolysis module 160 for conversion of at least a portion of the water substrate, and an Fh-enriched stream is passed via a conduit 164 to the CO-consuming process 140.
  • second Fh- enriched stream 163 from water electrolysis module 160 may be passed to CO 2 to CO conversion system 130.
  • CO 2 to CO conversion system is a rWGS unit
  • second Fh-enriched stream 163 from water electrolysis module 160 is passed to CO 2 to CO conversion system 130.
  • Figure 1A shows second Fh-enriched stream 163 as branching from Fh-enriched stream 164, however in other embodiments second H 2 -enriched stream 163 may be independent from Fh-enriched stream 164.
  • at least a portion of O 2 generated by the water electrolysis module 160 may be passed to the industrial process 110 via a conduit 166.
  • the CO-consuming process 140 produces at least one product 146 and a post-CO-consuming process gaseous substrate 142.
  • the CO-consuming process 140 of Figure lA may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • the CO-consuming process 140 may be a gas fermentation process in a bioreactor comprising a culture of at least one Cl -fixing microorganism.
  • a culture may be fermented to produce one or more fermentation products 146 and a post-fermentation gaseous substrate, such as CO-consuming process gaseous substrate 142.
  • the CO-consuming process 140 of Figure 1A comprises a CO 2 - producing reaction step.
  • a post-CO-consuming process gaseous substrate 142 comprises CO 2
  • at least a portion of the post-CO-consuming process gaseous substrate 142 is passed to one or more removal modules 150 to remove and/or convert one or more constituent 158.
  • a treated gas stream comprising CO 2 152 is then passed to CO 2 to CO conversion system 130 for conversion of at least a portion of treated gas stream comprising CO 2 152 or treated gas stream comprising CO 2 152 may be passed to the one or more removal modules 120 that receives the CO 2 -comprising gas 112 from the industrial process 110 .
  • the post-CO-consuming process gaseous substrate 142 is passed to the same one or more removal modules 120 that receives CO 2 -comprising gas 112 from the industrial process 110.
  • the post-CO-consuming process gaseous substrate 142 may be passed to the one or more removal modules 120 that receives the CO 2 - comprising gas 112 from the industrial process 110 This process of treating and converting CO 2 to CO of the post-CO-consuming process gaseous substrate has been found to increase carbon capture efficiency.
  • At least one constituent removed by the removal module 150 of Figures 1A is produced, introduced, and/or concentrated by the CO-consuming process 140, such as a gas fermentation process.
  • the one or more constituent produced, introduced, and/or concentrated by the fermentation step comprises sulfurcomprising compounds.
  • sulfur-comprising compounds such as hydrogen sulfide, is introduced to the CO-consuming process 140. This sulfur (present as sulfur - comprising compounds) was found to reduce the efficiency of the CO 2 to CO conversion system 130.
  • sulfur-comprising compounds may harm one or more catalysts used in different rWGS processes employed in specific embodiments as the CO 2 to CO conversion system
  • the one or more removal modules 150 was found to be successful at reducing the amount of sulfur-comprising compounds in the post-CO-consuming process gaseous substrate prior to the post-CO-consuming process gaseous substrate being passed to the CO 2 to CO conversion system 130.
  • the use of the removal module 150 prior to the CO 2 to CO conversion system 130 was found to increase the efficiency of the CO 2 to CO conversion system 130.
  • the O 2 by-product of water electrolysis processes employed, for example when the CO 2 to CO conversion process is a rWGS unit, can provide additional benefits for the Cl -generating industrial process, discussed above.
  • Specific embodiments of the fermentation processes of the current disclosure are anaerobic processes, and depending upon the technology selected for the CO 2 to CO conversion system, O 2 could be generated as a by-product and may be separated and passed through optional conduit 136 in of Figure 1A, to be used in the industrial process 110.
  • the optional O 2 by-product 136 of the CO 2 to CO conversion process 130 can be integrated with the industrial process 110 and beneficially offset costs, and in some cases, have synergy that further reduces costs for both the industrial process 110 as well as the subsequent gas fermentation.
  • the CO 2 to CO conversion system will not generate O 2 as a by-product.
  • the industrial processes described herein derive the required O 2 by air separation.
  • Production of O 2 by air separation is an energy intensive process which involves cryogenically separating O 2 from N2 to achieve the highest purity.
  • Production of O 2 by CO 2 conversion to CO as in line 136, depending upon the CO 2 to CO conversion system selected, and/or water electrolysis as in line 166, and displacing O 2 produced by air separation, could offset up to 5% of the electricity costs in an industrial process.
  • Gasification processes include, but are not limited to, gasification of coal, gasification of refinery residues, gasification of biomass, gasification of lignocellulosic material, black liquor gasification, gasification of municipal solid waste, gasification of industrial solid waste, gasification of sewerage, gasification of sludge from wastewater treatment, gasification of pet coke, reforming of natural gas, reforming of biogas, reforming of landfill gas or any combination thereof.
  • O 2 from the CO 2 to CO conversion system and/or 02 from water electrolysis may be used to off-set or completely replace the O 2 typically supplied through air separation.
  • a process for integration of an industrial process, one or more removal module, a CO 2 to CO conversion system, an optional water electrolysis process, and a CO-consuming process may further comprise integration of one or more pressure modules 170.
  • at least a portion of CO 2 - comprising gas 112 from an industrial process 110 is passed to pressure module 170 to produce a pressurized CO 2 -comprising gas stream 172.
  • At least a portion of the pressurized CO 2 - comprising gas stream 172 is then passed to a removal module 120.
  • At least a portion of post- CO-consuming process gaseous substrate 142 may also be passed pressure module 170 to produce a pressurized tail gas which is part of pressurized CO 2 -comprising gas stream 172.
  • pressure module 170 As shown in Figure 1 C, at least a portion of a converted gas stream 132 is passed from CO 2 to CO conversion system 130 to pressure modules 170 to produce pressurized CO-comprising gas stream 172, which is passed CO-consuming process 140.
  • Figure 2 shows a process for integration of an industrial process 210, a removal module 220, a CO 2 to CO conversion system 230, an optional water electrolysis process 270, a CO- consuming process 240, and an optional O 2 separation module 260.
  • the CO 2 to CO conversion system 230 is selected to be a rWGS unit.
  • CO 2 -comprising gas 212 from an industrial process 210 is passed to one or more removal modules 220 to remove and/or convert one or more constituent 228.
  • the treated gas 222 from the one or more removal module 220 is then passed CO 2 to CO conversion system 230 for conversion of at least a portion of the CO 2 in treated gas stream 222.
  • At least a portion of O 2 may be fed from the CO 2 to CO conversion system 230 to the industrial process 210 via a conduit 236. At least a portion of the converted gas stream 232 is passed from the CO 2 to CO conversion system 230 to the CO-consuming process 240 to produce a product 246 and a post-CO-consuming process gaseous substrate 242.
  • a water substrate 272 is introduced to water electrolysis module 270 for conversion of at least a portion of the water substrate to generate an H 2 -enriched stream 274 which is passed to the CO- consuming process 240.
  • a portion of H 2 -enriched stream 274 may be passed in stream 273 to CO 2 to CO conversion system 230.
  • at least a portion of O 2 generated by water electrolysis module 270 may be passed in O 2 stream 276 to the industrial process 210.
  • the process includes an O 2 separation module 260 following the CO 2 to CO conversion system 230 to separate at least a portion of O 2 from the gas generated in CO 2 to CO conversion system 230.
  • an O 2 separation module 260 downstream of CO 2 to CO conversion system 230 at least a portion of gas stream 234 is fed from the CO 2 to CO conversion system 230 to O 2 separation module 260.
  • an O 2 -enriched stream 264 may be passed industrial process 210 thereby displacing the need for other sources of O 2 in industrial process 210.
  • O 2 separation module 260 downstream of CO 2 to CO conversion system 230 at least a portion of the O 2 -lean stream 262 is passed from O 2 separation module 260 to the CO- consuming process 240. In some embodiments utilizing an O 2 separation module 260 downstream of CO 2 to CO conversion system 230, at least a portion of the O 2 -lean stream 262 is passed from O 2 separation module 260 back to the CO 2 to CO conversion system 230 in line 266. In embodiments not utilizing an O 2 separation module 260, a portion of the gas stream 236 may be passed from the CO? to CO conversion system 230 to the industrial process 210.
  • the CO-consuming process 240 of Figure 2 comprises a CO 2 - producing reaction step.
  • the post-CO-consuming process gaseous substrate comprises CO 2
  • at least a portion of the post-CO-consuming process gaseous substrate is passed via a conduit 242 to one or more removal module 250 to remove and/or convert one or more constituent 258.
  • a treated gas stream 252 is then passed CO 2 to CO conversion system 230 for conversion of at least a portion of the treated gas stream 252.
  • the post-CO-consuming process gaseous substrate 242 is passed to the same one or more removal module2 220 that receives the CO 2 -comprising gas 212 from the industrial process 210.
  • the post-CO-consuming process gaseous substrate 242 and 252 may be passed to the one or more removal modules 220 that receives the CO 2 -comprising gas 212 from the industrial process 210 and the one or more removal modules 250.
  • the CO-consuming process 240 of Figure 2 may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • the CO-consuming process 240 may be a gas fermentation process in a bioreactor comprising a culture of at least one Cl -fixing microorganism.
  • a culture may be fermented to produce one or more fermentation products such as post CO-consuming process product 246 and a post- fermentation gaseous substrate such as the post-CO-consuming process gaseous substrate 242.
  • a CO 2 concentration module may be incorporated in the process.
  • the CO-enriched stream generated by the CO 2 to CO conversion system, such as a rWGS unit, stream may have a concentration of CO between 20-90%.
  • FIG. 3 shows a process for integration of an industrial process 310 with an optional CO 2 concentration module 370, a removal module 320, a CO 2 to CO conversion system 330, an optional water electrolysis module 380, a CO-consuming process 340, and an optional O 2 separation module 360, in accordance with one aspect of the disclosure.
  • CO 2 -comprising gas 312 from the industrial process 310 is passed to a removal module 320.
  • CO 2 -comprising gas 314 from the industrial process 310 is passed to CO 2 concentration module 370 in order to increase the concentration of CO 2 in the gas stream and to remove one or more constituent 374.
  • the CO 2 -concentrated gas stream 372 is passed to one or more removal modules 320 to remove and/or convert one or more constituent 328.
  • the treated gas 322 from the one or more removal module 320 is then passed to CO 2 to CO conversion system 330 for conversion of at least a portion of treated gas stream 322.
  • CO 2 to CO conversion system 330 may be a rWGS unit.
  • At least a portion of converted gas stream 332 is passed from the CO 2 to CO conversion system 330 to CO-consuming process 340.
  • the constituent 374 is CO and/or H 2 , which is passed via conduit 376 to CO- consuming process 340.
  • a water substrate 382 is fed to water electrolysis module 380 for conversion of at least a portion of water substrate 382, to generate H 2 -enriched stream 384 which is passed to CO-consuming process 340.
  • a portion of H 2 - enriched stream 384 may be passed to CO 2 to CO conversion system 330 in stream 383.
  • an independent H 2 -enriched stream may be passed from water electrolysis module 380 to CO 2 to CO conversion system in lieu of or in addition to stream 383 (not shown).
  • at least a portion of O 2 -enriched stream 386 generated by water electrolysis module 380 may be passed to industrial process 310.
  • At least a portion of the gas stream 336 from the CO 2 to CO conversion system 330 may be passed to the industrial process 310.
  • the process includes an O 2 separation module 360 following the CO 2 to CO conversion system 330, where the gas stream 334 is passed from the CO 2 to CO conversion system 330 to the O 2 separation module 360 to separate at least a portion of O 2 from the gas stream 334.
  • O 2 separation module 360 after the CO 2 to CO conversion system 330, at least a portion of the O 2 - enriched stream 364 is passed from O 2 separation module 360 to industrial process 310.
  • At least a portion of the O 2 -lean stream 362 is passed from O 2 separation module 360 to CO-consuming process 340.
  • at least a portion of the O 2 -lean stream 366 is passed from the O 2 separation module 260 back to CO 2 to CO conversion system 330.
  • a portion of the gas stream 336 may be passed from the CO 2 to CO conversion system 330 to industrial process 310.
  • the CO-consuming process 340 of Figure 3 comprises a CO 2 - producing reaction step.
  • the post-CO-consuming process gaseous substrate comprises CO 2
  • the post-CO-consuming process gaseous substrate 342 is passed to one or more removal modules 350 to remove and/or convert one or more constituent 358.
  • the treated gas stream 352 is then passed to CO 2 to CO conversion system 330 for conversion of at least a portion of treated gas stream 352.
  • the post-CO-consuming process gaseous substrate 342 is passed to the one or more removal modules 320 that receives the CO 2 -comprising gas 312 and or 372 from industrial process 310.
  • the post-CO-consuming process gaseous substrate 342 and 352 may be passed to the one or more removal modules 320 that receives the CO 2 -comprising gas 312 and or 372 from industrial process 310 and one or more removal modules 350.
  • the CO-consuming process 340 of Figure 3 may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • the CO-consuming process may be a gas fermentation process in a bioreactor comprising a culture of at least one Cl -fixing microorganism.
  • a culture may be fermented to produce one or more fermentation products such as post CO-consuming process product 346 and a post-fermentation gaseous substrate, such as the post-CO-consuming process gaseous substrate 342.
  • a CO 2 concentration module may be placed after a removal module.
  • Figure 4 shows a process for integration of an industrial process 410 with a removal module 420, an optional CO 2 concentration module 470, a CO 2 to CO conversion system 430, an optional water electrolysis module 480, a CO-consuming process 440, and an optional O 2 separation module 460, in accordance with one aspect of the disclosure.
  • CO 2 -comprising gas 422 from the industrial process 410 is passed from removal module 420 to the CO 2 to CO conversion system 430.
  • CO 2 -comprising gas 412 from the industrial process 410 is passed to one or more removal modules 420 to remove and/or convert one or more constituent 428.
  • Resulting treated stream 424 is then passed to optional CO 2 concentration module 470 in order to increase the concentration of the CO 2 in CO 2 -concentrated gas stream 472 and remove one or more constituent 474.
  • CO 2 -concentrated gas stream 472 is then passed CO 2 to CO conversion system 430 for conversion of at least a portion of the gas stream. At least a portion of the converted gas stream 432 may be passed from the CO 2 to CO conversion system 430 to the CO-consuming process 440.
  • the constituent 474 is CO and/or hb, which is passed via conduit 476 to CO- consuming process 440.
  • water substrate 482 is fed to water electrolysis module 480 for conversion of at least a portion of water substrate 482, to generate H 2 -enriched stream 484 is passed to CO-consuming process 440.
  • a portion of hb- enriched stream 484 may be passed to CO 2 to CO conversion system 430 in stream 483.
  • an independent H 2 -enriched stream may be passed from water electrolysis module 480 to CO 2 to CO conversion system in lieu of or in addition to stream 483 (not shown).
  • at least a portion of O 2 -enriched stream 486 generated by water electrolysis module 480 may be passed to industrial process 410.
  • At least a portion of the gas stream 436 from the CO 2 to CO conversion system 430 may be passed to the industrial process 410.
  • the process includes O 2 separation module 460 following the CO 2 to CO conversion system 430 to separate at least a portion of O 2 from the gas stream 434.
  • O 2 separation module 460 after the CO 2 to CO conversion system 430, at least a portion of the gas stream 464 is fed from the O 2 separation module 460 to the industrial process 410.
  • at least a portion of the O 2 - lean stream 462 is passed from O 2 separation module 460 to CO-consuming process 440.
  • At least a portion of the O 2 -lean stream 466 is passed from the O 2 separation module 460 back to the CO 2 to CO conversion system 430.
  • a portion of the gas stream 436 may be passed from the CO 2 to CO conversion system 430 to the industrial process 410, particularly if the selected CO 2 to CO conversion system 430 generates O 2 .
  • the CO-consuming process 440 of Figure 4 comprises a CO 2 - producing reaction step.
  • a post-CO-consuming process gaseous substrate comprises CO 2
  • at least a portion of the post-CO-consuming process gaseous substrate 442 is passed to one or more removal modules 450 to remove and/or convert one or more constituents 458.
  • the treated gas stream 452 is then passed to CO 2 to CO conversion system 430 for conversion of at least a portion of the treated gas stream 452.
  • the post-CO-consuming process gaseous substrate 442 is passed to the same one or more removal modules 420 that receives the CO 2 -comprising gas 412 from the industrial process 410.
  • the post-CO-consuming process gaseous substrate 442 and 452 may be passed to the one or more removal modules 420 that receives the CO 2 -comprising gas from the industrial process 410 and one or more removal modules 450.
  • the CO-consuming process 440 of Figure 4 may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • the CO-consuming process 440 may be a gas fermentation process in a bioreactor comprising a culture of at least one Cl -fixing microorganism.
  • a culture may be fermented to produce one or more fermentation products such as post CO-consuming process product 446 and a post-fermentation gaseous substrate, such as the post-CO-consuming process gaseous substrate 442.
  • FIG. 5 shows a process for integration of an industrial process 510 with a removal module 520, optional CO 2 concentration modules 570, a CO 2 to CO conversion system 530, a CO-consuming process 540, an optional O 2 separation module 560, an optional pressure module 580, and an optional water electrolysis module 1500, in accordance with one aspect of the disclosure.
  • CO 2 -comprising gas 512 from the industrial process 510 is passed to one or more removal modules 520 to remove and/or convert one or more constituent 528.
  • the treated gas 522 from the one or more removal module 520 is then passed to CO 2 to CO conversion system 530 for conversion of at least a portion of the gas stream 522.
  • a water electrolysis module 1500 may generate and pass a H 2 -rich gas stream 1502 to be blended with the optionally pressurized converted gas stream 582 prior to being introduced to the CO-consuming process 540.
  • the disclosure provides one or more pressure modules 580 to increase the pressure of the converted gas 532 from the CO 2 to CO conversion system 530.
  • at least a portion of the gas stream 532 is passed from CO 2 to CO conversion system 530 to pressure module 580 which increases the pressure of gas stream 532 and generates increased pressure stream 582 which is passed to CO-consuming process 540.
  • water electrolysis module 1500 is incorporated along with the O 2 separation module 560 and/or the pressure module 580.
  • a water substrate 1506 is introduced to water electrolysis module 1500, and EE-rich gas stream 1502 is blended with the converted gas stream 582 prior to converted gas stream 582 being introduced to CO-consuming process 540.
  • EE-rich gas stream 1504 is passed directly from water electrolysis module 1500 to CO-consuming process 540.
  • an EE-enriched stream 1510 may be passed from water electrolysis module 1500 to CO 2 to CO conversion system 530.
  • at least a portion of O 2 -enriched stream 1508 generated by water electrolysis module 1500 may be passed to industrial process 510.
  • the disclosure integrates an industrial process 510, an optional CO 2 concentration module 570, a removal module 520, a CO 2 to CO conversion system 530, an optional O 2 separation module 560, an optional pressure module 580, an water electrolysis module 1500, and a CO-consuming process 540, in accordance with one aspect of the disclosure.
  • CO 2 -comprising gas 514 from the industrial process 510 is passed to an optional CO 2 concentration module 570 to increase the concentration of the CO 2 in the gas stream 514 and remove one or more constituent 574.
  • a first CO 2 concentrated stream 572 from first CO 2 concentration module 570 is passed to removal module 520 to remove and/or convert one or more constituent 528.
  • the treated stream 524 is then passed to a second optional CO 2 concentration module 570 to increase the concentration of the CO 2 in the gas stream 524 and remove one or more constituent 574.
  • a second CO 2 concentrated stream 572 is passed to a CO 2 to CO conversion system 530 for conversion of at least a portion of the second CO 2 concentrated stream 572.
  • At least a portion of the converted gas stream 534 may be passed to an optional O 2 separation module 560 to separate at least a portion of O 2 from the converted gas stream 534.
  • At least a portion of the O 2 -rich gas stream 564 may be passed from the optional O 2 separation module 560 to the industrial process 510.
  • At least a portion of the O 2 -rich gas stream may be fed from the CO 2 to CO conversion system 530 to the industrial process 510 via a conduit 536, if the selected CO 2 to CO conversion system 530 generates O 2 .
  • At least a portion of the 02-depleted gas stream 562 may be passed from the optional O 2 separation module 560 to an optional pressure module 580.
  • the pressurized gas stream 582 from the optional pressure module 580 is passed to the CO-consuming process 540.
  • the pressurized gas stream 582 may be blended with an H 2 -rich gas stream 1502 prior to being introduced to the CO-consuming process 540.
  • the CO-consuming process 540 of Figure 5 produces product 546 and post-CO- consuming process gaseous substrate 542.
  • the CO-consuming process may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • a culture may be fermented to produce one or more femientation products such as post CO-consuming process product 546 and a post-fermentation gaseous substrate, such as the post-CO-consuming process gaseous substrate 542 and or 544.
  • the post-CO-consuming process gaseous substrate 542 may be passed removal module 550 to remove and/or convert one or more constituent 558.
  • the post-CO-consuming process gaseous substrate 544 may be passed to an optional CO 2 concentration module 570 to increase the concentration of the CO 2 in stream 544 and remove one or more constituent 574.
  • Resulting CO 2 -enriched stream 572 is passed to removal module 550 to remove and/or convert one or more constituent 558.
  • the treated gas stream 552 may then be passed to CO 2 to CO conversion system 530 for conversion of at least a portion of the gas stream552.
  • post-CO-consuming process gaseous substrate 542 is passed, to the same one or more removal modules 520 that receives the CO 2 -comprising gas 512 from the industrial process 510.
  • the post-CO-consuming process gaseous substrate 542 may be passed to both the one or more removal modules 520 that receives the CO 2 -comprising gas 512 or 572 from the industrial process 510 and the one or more removal module 550.
  • the disclosure provides generally for the removal of constituents from the gas stream that may have adverse effects on downstream processes, for instance, the downstream femientation process and/or downstream modules.
  • the disclosure provides for one or more further removal module between the various modules in order to prevent the occurrence of such adverse effects.
  • the conversion of a CO 2 -comprising gaseous substrate by an CO 2 to CO conversion system results in one or more constituent passing through the CO 2 to CO conversion system 630. In various embodiments, this results in one or more constituent in the CO-enriched stream.
  • the constituent includes portions of converted O 2 .
  • the further removal module is a deoxygenation module for removing O 2 from the CO-enriched stream.
  • Figure 6 shows the integration of a CO 2 to CO conversion system 630, an optional O 2 separation module 660, an optional pressure module 680, with a further removal module 690.
  • the further removal module 690 is downstream of the CO 2 to CO conversion system 630.
  • at least a portion of the gas stream 632 from the CO 2 to CO conversion system 630 is passed to the further removal module 690.
  • the further removal module 690 removes and/or converts one or more constituents 698 in gas stream 632.
  • stream 662 from optional 02 separation module 660 is passed to further removal module 690 to remove and/or convert one or more constituents 698.
  • the treated stream 692 is then passed to an optional pressure module 680.
  • the disclosure integrates an industrial process 610, an optional CO 2 concentration module 670, a removal module 620, a CO 2 to CO conversion system 630, a further removal module 690, an optional O 2 separation module 660, an optional pressure module 680, an optional water electrolysis module 1600, and a CO-consuming process 640, in accordance with one embodiment of the disclosure.
  • the C 02-comprising gas 612 from the industrial process 610 is passed to the removal module 620.
  • the CO 2 -comprising gas 614 from the industrial process 610 is passed to an optional CO 2 concentration module 670 to increase the concentration of the CO 2 in the gas stream 614 and remove one or more constituent 674.
  • the gas stream having increased CO 2 concentration 672 from optional CO 2 concentration module 670 is passed to removal module 620, to remove and/or convert one or more constituents 628.
  • the treated stream 622 is passed from removal module 620 to CO 2 to CO conversion system 630.
  • the treated stream 624 is then passed to an optional CO 2 concentration module 670 to increase the concentr ation of the CO 2 in the treated stream 624 and remove one or more constituents 674.
  • the resulting CO 2 enriched stream 672 is passed from optional CO 2 concentration module 670 to CO 2 to CO conversion system 630 for conversion of at least a portion of CO 2 enriched stream 672.
  • O 2 may be generated, and if so, at least a portion of a O 2 -rich gas stream 636 may be passed from the CO 2 to CO conversion system 630 to industrial process 610. At least a portion of CO-rich gas stream 632 may be passed to a further removal module 690 to remove and/or convert one or more constituents 698. At least a portion of the treated gas stream 634 may be passed to an optional O 2 separation module 660 to separate at least a portion of O 2 from treated gas stream 634. At least a portion of the O 2 -enriched gas stream 664 may be passed from the optional O 2 separation module 660 to the industrial process 610. At least a portion of the O 2 -depleted gas stream 662 may be passed from the optional O 2 separation module 660 to the further removal module 690 to remove and/or convert one or more constituents 698.
  • At least a portion of the gas stream 692 may be passed from the further removal module 690 to an optional pressure module 680.
  • the pressurized gas stream 682 from the optional pressure module 680 is passed to CO-consuming process 640.
  • the gas stream 692 may be blended with a H 2 -rich gas stream 1602 prior to being introduced to the CO-consuming process 640.
  • a water substrate 1606 may be passed a water electrolysis module 1600 to generate H 2 - rich gas stream 1602 discussed above, and/or H 2 -rich gas stream 1604 which may be passed from water electrolysis module 1600 directly to the CO-consuming process 640 via a conduit 1604.
  • O 2 produced by the water electrolysis module 1600 may be passed in O 2 stream 1608 to the industrial process 610.
  • the CO-consuming process 640 of Figure 6 may produce product 646 and a post CO- producing process gaseous substrate 642 and 644.
  • the CO-consuming process may be a gas fermentation process and may occur in an inoculator and/or one or more bioreactors.
  • a culture may be fermented to produce one or more fermentation products such as post CO-consuming process product 646 and a post-fermentation gaseous substrate, such as the post-CO-consuming process gaseous substrate 642 or 644.
  • the post-CO-consuming process gaseous substrate 644 is passed to an optional CO 2 concentration module 670 to increase the concentration of the CO 2 in the gas stream 644 and remove one or more constituent 674.
  • Resulting stream 672 is passed from optional CO 2 concentration module 670 to removal module 650 to remove and/or convert one or more constituent 658.
  • the treated gas stream 652 is then passed to CO 2 to CO conversion system 630 for conversion of at least a portion of the gas stream.
  • the post-CO-consuming process gaseous substrate 642 or 642/672 is passed to the same one or more removal modules 620 that receives the CO 2 -comprising gas 612 or 672 from the industrial process 610.
  • the post-CO-consuming process gaseous substrate 642 or 642/672 may be passed to the one or more removal modules 620 that receives the CO 2 - comprising gas 612 or 672 from the industrial process 610 and the treated gas stream 652 from the one or more removal modules 650.
  • the disclosure provides an integrated process comprising electrolysis of water to provide at least hydrogen and optionally oxygen, wherein the power supplied for the water electrolysis process is derived, at least in part, from a renewable energy source.
  • the substrate is typically gaseous
  • the substrate may also be provided in alternative forms.
  • the substrate may be dissolved in a liquid saturated with a CO- comprising gas using a microbubble dispersion generator.
  • the substrate may be adsorbed onto a solid support.
  • the C 1 -fixing microorganism in a bioreactor is typically a carboxydotrophic bacterium.
  • the carboxydotrophic bacterium is selected from the group comprising Moorella, Clostridium, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, Methanosarcina, and Desulfotomaculum.
  • the carboxydotrophic bacterium is Clostridium autoethanogenum.
  • any concentration range, percentage range, ratio range, integer range, size range, or thickness range is to be understood to include the value of any integer within the recited range and, when appropriate, fractions thereof (such as one tenth and one hundredth of an integer).
  • ratios are molar ratios, and percentages are on a weight basis.

Abstract

La présente invention prévoit l'intégration d'un procédé consommateur de CO, tel qu'un procédé de fermentation gazeuse, avec un système de conversion de CO2 en CO. La présente invention est capable d'utiliser un substrat gazeux comprenant du CO2 généré par un processus industriel et prévoit un ou plusieurs modules d'élimination pour éliminer au moins un constituant d'un substrat gazeux comprenant du CO2 avant le passage du substrat gazeux dans un système de conversion de CO2 en CO. La divulgation peut également comprendre un ou plusieurs modules de pression, un ou plusieurs modules de concentration de CO2, un ou plusieurs modules de séparation de O2, et/ou un module d'électrolyse de l'eau. L'efficacité de la conversion du carbone est augmentée en recyclant le CO2 produit par un processus consommateur de CO vers le processus de conversion du CO2 en CO.
PCT/US2022/071637 2021-04-09 2022-04-08 Procédé d'amélioration de l'efficacité de conversion de carbone WO2022217280A1 (fr)

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JP2023560267A JP2024514490A (ja) 2021-04-09 2022-04-08 炭素変換率を改善するための方法
AU2022253075A AU2022253075A1 (en) 2021-04-09 2022-04-08 Process for improving carbon conversion efficiency
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US20230105160A1 (en) * 2021-10-03 2023-04-06 Lanzatech, Inc. Gas fermentation conversion of carbon dioxide into products

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JP2024514490A (ja) 2024-04-02
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